Weaving with binder interposed between pile and stuffer warp ends



F. w. E. HOESELBARTH 2,713,354 WEAVING WITH BINDER INTERPOSED BETWEEN July 19, 1955 PILE AND STUFFER WARP ENDS l2 Sheets-Sheet 1 Filed March 3, 1952 BY w. 33. I. -03

ORNEYS.

F w. E. HOESELBARTH 2,713,354

WEAVING WITH BINDER INTERPOSED BETWEEN PILE AND STUFFER WARP ENDS July 19, 1955 12 Sheets-Sheet 2 Filed March 3, 1952 lNVENR I Franz 144E. Hoesedarf.

y 19, 1955 F. w. E. HOESELBARTH 2,713,354

WEAVING WITH BINDER INTERPOSED BETWEEN FILE AND STUFFER WARP ENDS l2 Sheets-Sheet 3 Filed March 3, 1952 v dri' i g INVENTOR 1E Haed'e (6402 1.

July 19, 1955 Filed March 3, 1952 W. E. HOESELBARTH WEAVING WITH' BINDER INTERPOSED BETWEEN FILE AND STUFFER WARP ENDS l2 Sheets-Sheet 4 INVENTOR Franz WE- HoeseZZ arzfi y 19, 1955 F. w. E. HOESELBARTH 2,713,354

WEAVING WITH BINDER INTERPOSED BETWEEN FILE AND STUFFER WARP ENDS 12 sheets sheet 5 Filed March 5, 1952 INVENTOR Franz 14 57 Hoeselbartxi.

July 19, 1955 Filed March 3, 1952 F. w. E. HOESELBARTH 2,713,354 WEAVING WITH BINDER INTERPOSED BETWEEN FILE AND STUFFER WARP ENDS l2 Sheets-Sheet 6 INVENTOR Franz 144i? flaeselbarl'.

ATTORNEYS.

July 19, 1955 Filed March 3, 1952 F. W. E. HOESELBARTH WEAVING WITH BINDER INTERPOSED BETWEEN PILE AND STUFFER WARP ENDS l2 Sheets-Sheet '7 uymmmmm INVENTOR fianz WET Hoeselbartfiy 19, 1955 F. w. E. HOESELBARTH 2,713,354

WEAVING WITH BINDER INTERPOSED BETWEEN FILE AND STUFFER WARP ENDS l2 Sheets-Sheet 8 Filed March 3, 1952 lNVENTOR M6022 ME fiaeseiarzi.

ATTORNEYS- J ly 1955 F. w. E. HOESELBARTH 2,

WEAVING WITH BINDER INTERPOSED BETWEEN PILE AND STUFFER WARP ENDS Filed March 3, 1952 12 Sheets-Sheet 9 INVENTOR Franz n46. Hoeselbar 6/1 July 1955 F. w. E. HOESELBARTH 2,713,354

WEAVING WITH BINDER INTERPOSED BETWEEN 7 FILE AND STUFFER WARP ENDS Filed March 3, 1952 12 Sheets-Sheet 10 nil INVENTOR Franz n ffloeselartfi- July 19, 1955 Filed March 3, 1952 F. W. E. HOESELBARTH WEAVING WITH BINDER INTERPOSED BETWEEN PILE AND STUFFER WARP ENDS l2 Sheets-Sheet ll INVENTOR Franz Ha esebarffi.

F. w. E. HOESELBARTH 2,713,354 WEAVING WITH BINDER INTERPOSED BETWEEN PILE AND STUFFER WARP ENDS July 19, 1955 12 Sheets-Sheet 12 Filed March 3, 1952 lNVE TOR Franz WE. Hoesel arf/i ATTQ RN EYS United States Patent 0 WEAVING WITH BINDER INTERPOSED BETWEEN FILE AND STUFFER WARP ENDS Frank W. E. Hoeselbarth, Cariisle, Pa., assignor to C. H.

Masland & Sons, Carlisle, Pa., a corporation of Pennsylvania Application March 3, 1952, Serial No. 274,567

39 Claims. (Cl. 139-39) The present invention relates to pile fabrics, particularly floor coverings.

A purpose of the invention is to obtain a tighter bind at the back of the fabric on the pile yarn, especially by increasing the number of oppositions obtained in the weave.

A further purpose is to oppose single binder ends to stuffer warp ends and pile warp ends, to separate the pile warp ends per dent with or without stuifer warp ends by binder warp ends and to separate stuffer warp ends per dent independent of the pile warp ends by binder warp ends.

A further purpose is to interpose single binder warp ends between the pile warp end or ends with or without a stulfer warp end or ends in a particular dent and an independent stuffer warp end or ends in that dent.

A further purpose is to separate the pile warp per dent from all other warps on either side by a single end of the binder warp at each side woven in opposition to the pile warp.

A further purpose is to employ a plurality of stulfer warp ends in a particular dent and to separate them from the pile warp ends by single binder warp ends on either side.

A further purpose is to improve the appearance of the back of a woven pile fabric especially by creating a col) r pattern at the back of the fabric without requiring a special jacquard.

A further purpose is to segregate the pile end or ends with or without a stuffer warp end or ends in a single frame, two frame, three frame, four frame, five frame, six frame or the like pile fabric by placing the single ends of binder warp Woven in opposition on the two sides of the pile warp ends of all of the frames per dent.

A further purpose is to force the rejected pile warp end or ends reliably to the back of the fabric and prevent forcing the suffer warp end to the back, and in a two frame fabric to produce the pattern in reverse on the back of the fabric.

-A further purpose is to obtain better control of pile and stufier warp ends in weaving by more frequent interposition of binder warp ends.

A further purpose is to increase the number of crossings weftwise in a pile fabric by interposing binder warp ends woven in opposition between each of two groups of pile and/ or stuffer warp ends per dent.

A further purpose is to provide in each dent one or more stuifer Warp ends beside one or more pile warp ends, and one or more stufifer warp ends independent of the pile warp ends, and to interpose a binder warp end or ends woven in opposition to the stuffer and pile warp ends between the respective pile warp ends with stuffer warp ends and the independent stuffer warp end or ends of the particular dent and between the respective pile warp ends with stuffer warp ends of that dent and the independent stuifer warp end or ends of the next dent.

2,713,354 Fat-exited July 19, 1955 A further purpose is to reduce lateral shrinkage of pile fabrics.

A further purpose is to vary the thread-in in one fabric area with respect to that in another fabric area of the same fabric by varying at least one of the following characteristics:

1. The number of pile warp ends grouped together between binder warp ends.

2. The presence of stuffer warp ends with the pile warp ends between the binder warp ends, or the absence thereof.

3. The number of stuffer warp ends with the pile warp ends between the spaced binder warp ends.

4. The position of the stufler Warp ends with respect to the pile warp ends in the group between the spaced binder warp ends.

5. The number of stuffer warp ends in each dent out side the group with the pile warp ends.

6. The position of the stuffer warp ends in each dent outside the group with the pile warp ends with respect to such group.

A further purpose is to bind the pile by a staggered W weave and to segregate the pile warp ends from the stuffer warp ends in each dent and in the next dent by interposing binder warp ends woven in opposition.

A further purpose is to interpose a pile warp end or ends with or without stuffer warp ends between a pile warp end or ends in that dent and a pile warp end or ends in the next dent, desirably to place a stuffer warp end or endsin each dent between the aforesaid binder warp end or ends in that dent and'another binder warp end or ends in that dent and to weave all binder warp ends in opposition to the pile warp ends and the stuffer warp ends.

Further purposes appear in the specification and in the claims.

In the drawings I have chosen to illustrate a few only of the numerous embodiments in which my invention may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory operation and clear demonstration of the principles involved.

Figures 1 and 2 are weave diagrams showing the production of a single frame Wilton weave according to the present invention, the diagrams being conventional Warp-wise showings of the heddle positions.

Figure 3 is a conventional thread-in diagram of one embodiment of the weave of Figures 1 and 2, showing three dents of the reed, and a portion of an adjoining dent.

Figures 3a, 3b, 3c, 3d and 3e are variants of Figure 3.

'Figure 4 is a conventional warp-wise diagram of the finishedfabric produced in the weave of Figures 1 and 2 using the thread-in of Figure 3, where the wires are cutting wires.

Figure 5 is a view similar to Figure 4 showing the weave where the wires are round or non-cutting wires.

Figures 6 to 10 are conventionally fragmentary elevations of wires which are employed in various forms of the weave of Figures 1 and 2.

Figures 11 and 12 are sections of adjoining wires of the wire set which will be employed in different embodiments of the weave of Figures 1 and 2.

Figures 13 to 16 are conventional warpwise weave diagrams of the weave of the invention applied to a two frame Wilton.

Figure 17 is a thread-in diagram similar to Figure 3 applied to the weave of Figures 13 to 16.

Figure 17a is a variation of Figure 17.

Figure 18 is a view similar to Figure 4 showing the fabric produced in the weave of Figures 13 to 16 using cutting wires.

Figure 19 is a view similar to Figure 18 showing the weave of Figures 1.3 to 16 as obtained from n0n-cutting wires.

Figures 20 to 23 are conventional warp-wise weave diagrams showing the invention as applied to a four frame velvet W Weave.

Figure 24 is a thread-in diagram similar to Figure 3 for the weave of Figures 20 to 23.

Figure 25 is a conventional diagram similar to Figure 4 of the completed weave of Figures 20 to 23, where the wires are cutting wires.

Figure 26 is a view similar to Figure 25 showing the weave of Figures 20 to 24 obtained with non-cutting wires.

In the drawings like numerals refer to like parts throughout.

Describing in illustration but not in limitation and referring to the drawings:

In the prior art it is usual in the manufacture of pile carpets to thread-in the pile warp ends in a particular dent in the following order:

Pile warp, one or more ends Stuffer warp, one or more ends Binder warp ends In the final weave, the pile lies in the front of the stuffer at the face of the fabric and the stuifer tends to mask the pile at the back of the fabric.

As the stuft'er is usually unattractive and usually formed from jute, the appearance at the back of the fabric is unattractive.

This thread-in of the prior art tends to create the following oppositions in the weave:

l. The stutfer warp end or ends of each dent versus one of the binder warp ends in that dent.

2. The two binder warp ends with respect to one another.

3. One of the binder warp ends in one dent and the pile warp ends.

An effort has been made to improve the appearance of the back of the fabric by weaving with a special jacquard which creates the same pattern on the back which is woven on the front. This greatly increases the expense of production.

In accordance with the present invention, the thread-in sequence is changed, a tighter bind is secured on the pile yarn and the appearance of the back of the fabric is greatly improved without increased cost.

In a typical illustration in accordance with the present invention the sequence of thread-in is as follows:

The stuffer warp end or ends of the particular dent A single binder warp end All of the pile warp ends of the particular dent A single binder warp end According to this embodiment the pile warp end or ends are separated from the stuffer warp end or ends in that dent and the next dent by a binder warp end, which is preferably a single binder warp end. In other words, a single binder warp end is placed on each side of the pile yarn in each dent where pile yarn appears L and separates the pile yarn from the stuffer warp. In some cases one of the separating binder warp ends will be in the next dent.

Furthermore in accordance with one aspect of the invention it is important to employ only a single binder warp and to weave the binder warp in opposition to the pile warps (those which are raised and those which are rejected) and the stutfer warp. By this means the stufier Warp in one embodiment is segregated from the pile warps and is not forced to the back of the fabric by the particular pile warp which is raised as in prior art practice. The tendency instead is to force one or more rejected pile warps to the back of the fabric and thus produce an attractive appearance.

The bind of the weave on the pile projections which are raised is improved in accordance with the invention.

The following oppositions are obtained in one embodiment of the invention:

1. The stutfer warp end or ends versus the adjoining binder warp end of the particular dent.

2. One binder warp end versus the pile warp end or ends of the particular dent.

3. The pile warp end or ends of the particular dent versus the other binder warp end of that dent.

4. The other binder warp end of that dent and the stuffer warp end or ends adjoining in the next dent.

Accordingly I find that the pile projections are more tightly locked in the present invention than in the comparable prior art thread-ins.

The appearance of the back of the fabric is greatly enhanced by this embodiment of the invention, especially in two frame, three frame, four frame, five frame, six frame, etc. fabrics. This is especially true in Wilton weav ing but is also true in brussels, velvet and tapestry carpet weaving. The tendency according to the invention is to force a rejected pile end or ends to the back of the fabric. in a two frame (two pile warp) pile carpet of this embodiment, the back of the fabric will show the pattern on the face in reverse. On a three frame, four frame, five frame, six frame, seven frame, eight frame, etc. fabric of this embodiment, the back will show a pattern different from the face, but often very attractive. In a single frame fabric the back will show the pattern of the face at least to some extent.

The reason that the appearance of the back is improved in this embodiment is that the stuffer warp ends do not have an opportunity to run under the selected pile ends and be forced to the back of the fabric when the pile ends are selected.

In some cases, the pattern effect on the back is not necessary. In such cases, the principles of the invention may still be applied to great advantage in order to obtain better control of the pile and stutfer warp ends in weaving by more frequent interposition of binder Warp ends, to secure better warpwise alignment of pile and stuffer warp ends, and to reduce lateral shrinkage in the carpet.

Accordingly in this aspect of the invention I will provide per dent one or more stuffer warp ends beside one or more pile warp ends, and one or more stuffer warp ends independent of the pile warp ends, and I will interpose a binder warp end or ends woven in opposition to the stuffer and pile warp ends between the respective pile Warp ends with stuffer warp ends, and the independent stuffer warp end or ends of the particular dent, and between the respective pile warp cnds with stuffer warp ends of that dent and the independent stulfer warp end or ends of the next dent (this last mentioned binder warp end or ends may be in either dent).

Thus in some cases the independent stulfer warp ends will be represented in a given dent by a single stuffer warp end and in other cases by two or more stutfer warp ends. In some cases the independent stuffer warp end or ends will be on one side of the binder warp ends with an enclosed pile warp end or ends with or without a stutfer warp end or ends, in other cases the independent stuffer warp end or ends will be on the other side, and

in still other cases the independent stulfer warp end or ends will be on both sides.

Inside the group per dent enclosed by the spaced binder warp end or ends woven together, the warp end or ends will in some cases consist of a pile warp end or ends exclusively, and in some cases of a pile warp end or ends beside a stulfer warp end or ends. The stuffer warp end or ends, where used with the pile warp end or ends, will in some cases be on one side of the pile warp end or ends, in other cases on the other side, in still other cases on both sides, and in still other cases among the pile warp ends.

. In some instances, unusual effects are achieved according to the invention by using one thread-in according to 75 the invention in certain groups of dents, and other threadins according to the invention in certain other groups of dents laterally displaced in the same fabric.

The invention is especially applicable in floor coverings such as pile carpets and rugs, and may be employed with any face pile yarn. The pile yarns in accordance with the invention will very often be of cotton, wool, rayon, nylon or some blend or combination thereof. I find that the invention is most applicable to carpets having a soft back in which the stutter warp ends and also the filler will usually be of cotton. The invention is, however, applicable also to carpets using jute, rayon or other suitable materials in the back.

The invention may be applied to any suitable weave, which may be wilton, brussels, velvet, tapestry or W weave, and may for example be applied to a staggered W weave in accordance with my application Serial No. 190,280, filed October 16, 1950, for Multiple Pile Staggered W-Weaving.

The invention may also be used to advantage in pile fabrics in which designs are produced suitably as block designs by raising a certain pile warp over aparticular character of wire in one pattern area and then raising it over a wire of a difierent character in another pattern area, so that another pile warp which was raised over a wire of one character in the first pattern area may be raised over a wire of another character in the second pattern area and thus the relative emphasis of the two pile warps in the two pattern areas may change in accordance with my corresponding application Serial No.

191,830, filed October 24, 1950, for Weaving Pile Fabric Having High and Low Loops and in continuation-in-part thereof, Serial No. 274,565, filed March 3, 1953, for Weaving Pile Fabric Having Textured Eifect, and Serial No. 274,566, March 3, 1952, for Method and Apparatus for Weaving Pile Fabric and Pile Fabric. It will be understood that this creation of designs by changing the character of wire over which a particular pile is raised may employ wires of any character in either pattern area to create novel effects.

The drawings illustrate by way of example several typical weaves which may be employed in the present invention.

In the weave of Figures 1 to 5 inclusive, using wires according to any of Figures 6 to 12 inclusive, I illustrate a single frame Wilton which is peculiar in the thread-in, l

but is suitably woven in a manner which in most respects may conform to conventional Wilton weaving. A pile warp is withdrawn from any suitable source, conveniently a creel 21 over suitable tensioning devices 22 and is manipulated from a jacquard or other suitable pattern control mechanism by lingoe heddles 23. A stuffer warp 24 is withdrawn from any suitable source, suitably a beam 25 over any desired tensioning device 26 and is manipulated by heddle 27. A single binder warp 28 is withdrawn from any suitable source, desirably a beam 30 over any desired tensioning device 31 and is manipulated by a heddle 32.

In Figure 1 binder warp 28 is raised half way by raising heddle 32, lingoe heddles 23 are lowered lowering pile warp 20, and stuffer warp heddle 27 is lowered lowering stuffer warp 24, thus forming a lower shed. A shot of weft 33 is inserted in the lower shed and beaten up by reed 34.

In the next step as shown in Figure 2, lingoe heddles 23 are fully raised as required by the pattern through the jacquard or other pattern control, raising pile warp 20 (any lingoe heddles not raised by the pattern being raised half way, not shown in Figure 2) and stutter warp heddle 27 is raised half way, raising the stutter warp 24 half way. Binder warp heddle 32 is lowered lowering binder warp 28. Thus an upper shed and a lower shed are formed. A shot of weft 33 is inserted in the lower shed and a wire 35 is inserted in the upper shed. The weft and the wire are beaten up by reed 34.

The wire 35 may be of any well known character and for example conforming to any of the wires shown in Figures 6 to 12 throughout the wire set.

For example, in some embodiments of the invention I employ a wire having a cutter 36 at the end remote from the head, as shown in Figure 6. In other embodiments of the invention I employ a wire having a round end 37 at the end remote from the head, thus creating an uncut transverse pile row. In some embodiments of the invention I employ a wire having a wavy upper surface 38 throughout the shed with a cutter 36 at the end remote from the head as shown in Figure 8, and in still other embodiments of the invention I employ a wire having a wavy upper surface 40 and a round or non-cutting wavy end 41 opposite to the head. The wires of Figures 8 and 9 create high and low pile in the same row and in the next transverse row. In other embodiments I employ a straight wire as shown in Figure 10 having a flag or noncutting raised portion 42 at the end remote from the head.

In this and each of the other embodiments of the invention, all of the wires of the set are in some cases of the same type except that in the case of the wavy wires the high and low points on different wires are at different positions along the length of the wire. In many embodi-' ments of the invention, however, I prefer to employ a combination of wires of different character, which are for example in one case straight cutting wires according to Figure 6 alternating with straight non-cutting wires according to Figure 7, in another case straight non-cutting wires of Figure 7 alternating with wavy non-cutting wires of Figure 9, in another case straight non-cutting wires of Figure 7 alternating with wavy cutting wires of Figure 8, in another case flag wires of Figure 10 alternating with straight non-cutting wires of Figure 7, or in another case flag wires of Figure 10 alternating with wavy non-cutting wires of Figure 9. In some cases combinations of several different kinds of wires are used, such as straight cutting wires of Figure 6, straight non-cutting wires of Figure 7, wavy non-cutting wires of Figure 9 and flag wires of Figure 10 all alternating; in another case straight non-cutting wires of Figure 7, wavy cutting wires of Figure 8, straight non-cutting wires of Figure 7 and wavy non-cutting wires of Figure 9 all alternating. It will be understood of course that the wires of the different types in certain embodiments of the invention are respectively high as shown at 43 in Figure 11 and low as shown at 44 alternating with one another, each of the wires 43 and 44 being of any one of the types shown in Figures 6 to 1 0. It will also be understood that in some embodimentsof the invention the wires as shown in Figure 12 are successively high wires 43, intermediate wires 45 and low wires 44, each being of any one of the types shown in Figures 6 to 10 inclusive.

The pile fabric according to the invention will appear as shown in Figure 4 if the pile is cut or as shown in Figure 5 if the pile is uncut. In this it is evident that the single binder warp 28 is woven in opposition to the pile warp 20 and to the stutfer warp 24. Unlike the usual pile fabric weaves, the stuirer warp is not forced to the back, and thus is not specially accented at the back at points 46 behind face wefts 33'. In the cut pile fabric pile tufts 47 stand up in the pile, and in the uncut .pile fabric pile loops 48 are upstanding.

The thread-in of the invention which contributes to the unusual effects described is shown in one embodiment in Figure 3. In this figure dents 50, 51, 52 and aportion of 53 of the reed are shown, which illustrate the thread-in employed throughout the fabric, or at least in a desired pattern area. It will be evident that each pile warp end 20 has a single binder warp end 28 interposed between it and the stutter warp end 24 on either side. Thus examining dent 50, pile warp end 20 in this dent is adjoined on the opposite sides by single binder warp ends 28, one of which is located between stufler warp end 24 in dent and the pile warp end 20, and the other of which is located between stutfer warp end 24 in dent 51 and the pile warp end 20 in dent 50. Since the binder warp is woven in opposition to the pile warp and to the stuffer warp, the single binder Warp ends 28 serve to separate the pile warp ends from the stuffer warp ends and improve the bind of the face yarn in the weave due to their location.

The thread-in of the warps in the dents of the reed may vary without departing from the invention. Figures 3a to 3e show other thread-ins which will in some cases be used in the weave of Figures 1 to 12, as well as in the other weaves of the invention.

Figure 3a differs from Figure 3 merely in respect to the inclusion of two stuffer warp ends 24 in each dent in Figure 30, rather than one as in Figure 3. This weave using the thread-in of Figure 30 has all of the advantages of Figure 3.

Figures 3 and 30 include no stufifer warp ends in the group of the pile warp end or ends and the binder warp end or ends on each side per dent. ever, stuifer warp ends are included with the pile warp end or ends even though this may prevent showing a pattern at the back of the fabric (as with two frames). The advantages of the invention in improved lateral control of pile and stuffer warp ends, improved straightness of pile and stuft'er warp ends, and reduced lateral shrinkage due to an increased number of lateral crossings of weft with respect to warp ends, all apply in the weaves using the thread-ins of Figures 3b to 3e.

Figures 31) to 3d include stuflfer warp ends with the pile warp end or ends and stuffer warp ends outside the group with the pile warp end or ends. The stuffer warp ends with the pile warp end or ends constitute a single end or ends on one side only of the pile warp end or ends, or a single end or ends on both sides of the pile warp end or ends.

In Figure 3b, the pile warp end 20 lies between stuffer warp ends 24 on either side, and is woven together with these stufifer warp ends. Binder warp ends 28 are on either side of these stuffer warp ends and woven in opposition. An independent stuffer warp end 24 lies outside and on the left of the group formed by the binder warp ends and is woven together with the pile and other stuifer warp ends.

The thread-in of Figure 3c is similar to that of Figure 3b except that there is only one stuffer warp end 24 in the group with the pile warp ends, and there are two independent stutter warp ends 24 outside the group and on the right in each dent.

The thread-in of Figure 3a is the same as that of Figure 30 except that the independent stutfer warp ends in each dent are one at the right and one at the left.

In some cases the binder warp end or ends on one side of the group of pile warp ends with or Without stutfer warp ends will be in the next dent rather than in the same dent. Thus in Figure 3e the pile warp end in each dent has on one side a binder warp end in that dent, and on the other side a binder warp end in the next dent. In the same dent on the side remote from the pile warp end, the binder warp end is adjoined by one or preferably two stutter warp ends and then by another binder warp end. The binder warp ends are all woven in opposition to the pile warp ends and to the stuifer warp ends.

The invention has special application in a two frame fabric such as a two frame wilton Whose weave is illustrated in Figures 13 to 19.

In Figures 13 to 16 an additional pile warp 20' is withdrawn from a suitable source such as a creel 21 over tensioning devices 22 and manipulated by lingoe heddles 23 according to the pattern requirements of a jacquard.

As shown in Figure 13 binder warp heddle 32 is raised half way, raising binder warp 28 half way, and lingoe heddles 23 and 23 and stutfer warp heddle 27 are lowered, lowering pile warps 2i) and 20' and stulfer warp In some cases, howand the stuffer Warp ends.

illustrates a unique effect.

24 and forming a lower shed. A shot of weft 33 is taken through the lower shed and beaten up by reed 34.

In the step shown in Figure 14, lingoe heddles 23 are fully raised as required by the jacquard raising pile warp 23, lingoe heddles 23' are raised half way raising pile warp 2t) half way, and stufier warp heddle 27 is raised half way raising stutfer warp 24 half way, and thus forming an upper shed through which wire 35 is inserted. Binder warp heddle 32 is lowered, lowering binder Warp 28 to form a lower shed, a shot of weft 33 is inserted through the lower shed. The wire and the weft are beaten up by reed 34.

The step of Figure 15 repeats that of Figure 13.

In the step of Figure 16, lingoe heddles 23 are fully I raised raising pile warp 2%) as the jacquard or other pattern mechanism requires, while lingoe heddles 23 are raised half way raising pile warp 20 half way, and stuffer warp heddle 27 is raised half way raising stuffer warp 24 half way and thus forming an upper shed, in which pile wire 35 is inserted. Binder warp heddle 32 is lowcred, thus lowering binder warp 28 and forming a lower shed, in which a shot of weft 33 is taken. The weft and wire are beaten up by reed 34.

The thread-in employed in Figures 13 to 16 is the same as that shown in Figure 3 except that multiple ends of pile warp and multiple ends of stuffer warp are provided side by side as shown by Figure 17. Any of the threadins of Figures 3a to 30! will in some cases be used in the Weave of Figures 13 to 16.

As shown in Figure l7, pile Warp ends 20 and 20 are placed side by side in each dent and are woven together (as far as the weave is concerned, although they are raised over different wires as the pattern requires), while single binder warp ends 28 are on either side of the pile warp ends of a particular dent, interposed between the pile warp ends and the adjoining independent multiple stulfer warp ends 24. It will be understood that any desired number of pile warp ends will be placed side by side and any desired number of independent stufier warp ends will be 7 placed side by side, but that a binder warp end will be interposed between each group of pile warp ends and each group of independent stufier warp ends, and the binder warp end is woven in opposition to the pile warp ends While the invention finds its widest application in weaves employing isolated binder Warp ends to separate the pile warp ends and the stuffer warp ends, I will where desired employ multiple binder Warp ends together as separators, as shown in Figure 1711, but in this case the multiple binder warp ends will be woven together, instead of in opposition as in the prior art.

It will be understood that any of the wire combinations of Figures 6 to 12 inclusive will be applied in different embodiments of the weave of Figures 13 to 19 inclusive,

with wires of different characters alternating as already explained.

As illustrated in Figures 18 and 19 which respectively show cut and uncut fabrics obtained from the weaving procedure of Figures l3 to 17, the fabric of the invention The combination of the special thread-in of Figures 3, 3(1, 17 or 17a and of the weaving of the binder warp in opposition to the pile warp ends and the stulfer warp ends forces the rejected pile warp ends to the back of the fabric instead of forcing the stuffer warp ends to the back as in prior art practice. Thus the pattern shows in reverse on the back of the fabric, creating novel and interesting effects. For example, at 54 in Figures l8 and 19 where pile 2G is the selected pile and pile 2% is the rejected pile, pile 20 is forced to the back of the fabric behind pile 20', and shows at the back. At a point of pattern change 55 the pile warp which has formerly been rejected remains at the back.

In the case of the pile fabrics woven with more than two frames, it will be understood that there is a tendency to force all the rejected pile warp ends to the back, and the designer by choice of the thread-in among the rejected pile warp ends determines which pile warp will show at the back when another warp is selected.

Figure 18 shows the weave produced in Figures 13 to 17 as a cut pile Wilton carpet, and Figure 19 shows the weave of Figures 13 to 17 as an uncut pile wilton carpet.

The weave of Figures 20 to 26 illustrates the application of the invention in a velvet carpet weave, and also to a weave having more than two frames (in this case four frames) and furthermore in a staggered W weave in accordance with my patent application relating to the same above referred to. It will be understood that the velvet weave will be applied using any desired number of frames, and using a conventional velvet weave instead of the W weave if desired. 3

In the form of Figures 20 to 23, the sources of pile yarn will desirably be beams instead of creels. In addition to the warps already referred to, I employ in Figures 20 to 23 pile warp 20 and 20 withdrawn from beams 21 and 21 withdrawn over tensioning devices 22 and 22 The pile warps in this case are respectively manipulated by heddles 23 23 23 and 23 as well known in velvet weaving.

In the position of Figure 20, binder warp heddle 32 is raised half way raising binder warp 28 half way, and all other heddles are lowered, lowering pile warps 20, 20 and 20 and creating a lower shed through which a shot of weft 33 is taken. The shot is beaten up by reed 34.

In the second step as shown in Figure 21, pile warp heddle 23 is raised, raising pile warp 20, while pile warp heddles 23 23 and 23 and stufl'er warp heddle 27 are raised half way, raising pile warps 20', 2t) and 20 and stuffer warp 24 half way, and creating an upper shed through which wire 35 is inserted. Wire 35 is any of the wires of Figures 6 to 12 in any of the combinations of the same or a different wire previously referred to. Binder warp heddle 32 is lowered lowering binder warp 28 and creating a lower shed through which a shot of weft 33 is'inserted. The wire and weft are beaten up by reed 34.

The next step shown in Figure 22 is the same as that of Figure 20. I

In Figure 23 a different pile warp is raised, pile warp heddle 20 being up to raise pile warp 20' and pile warp heddles 23 23 and 23 and stuffer warp heddle 27 are raised half way to raise pile warps 20, 20 and 20 and stutfer warp 24 half way and create an upper shed through which wire 35 is inserted. Wire 35 is any one of the wires of Figures 6 to 12 in any one of the combinations of the same or a different wire previously referred to. Binder warp heddle 32 is lowered lowering binder warp 28 to create a lower shed through which a shot of weft 33 is inserted. The wire and the weft are beaten up byreed 34.

This sequence desirably completes the cycle, unless of course it is desired to continue raising successive warps on successive alternate steps until warps 20 and 20 have been raised over wires, before again raising warp 20 in the pile. In the present invention, however, due to the fact that rejected warps show at the back of the fabric there is an advantage in many cases in carrying warps which do not appear at the front of the fabric. This may conveniently be the procedure followed with warps 20 and 20 in which case the steps of the weave will end with Figure 23 and repeat again with Figure 20. By special thread-in of the pile warp ends among themselves ineachdent, the pile warp ends which are rejected can be favored to make them travel to the back of the fabric.

The thread-in for the weave of Figures 20 to 23 is similar to those already described, and is shown in Figure 24, where in each dent pile warp ends 20, 20', 20 and 20 are side by side, and single binder warp ends 28 are immediately on either side of the pile warp ends, and between the pile warp ends and the stuffer warp ends 24.

The final staggered W weave produced in Figures 20 to 23 is shown in Figure 25 for the cut fabric and Figure 26 for the uncut fabric. From this it is seen that pile warps 20 and 20' are raised in the pile in alternate transverse rows, while pile warps 20 and 2.0 are continuously rejected to the back of the fabric and appear at points at the back, contributing a pattern effect at the back of the fabric.

It will be understood that in Figures 25 and 26 the single ends of pile warp are interposed between the binder warp and the stuffer warp, and woven in opposition to the pile warp and to the stufier warp.

In order to preferentially determine that one or another of a plurality of rejected pile warps will appear at the back of the fabric, the thread-in among pile warps of a particular dent may be varied as desired.

It will be evident that by the invention the bind of the back of the fabric on the pile yarn is increased in tightness, by securing more and better oppositions in the weave.

It will also be evident that by the invention the stuffer warp can be prevented from being forced to the back of the fabric since it can be separated from the pile warp by the binder ends, while at the same time the rejected pile warp ends are forced to the back of the fabric, and in the case of a two frame pile fabric a pattern is obtained at the back which is opposite to the pattern at the face.

It will further be evident that the invention is believed to find its widest application in very pliable backed carpet fabrics, such as those having cotton stuifer warp and cotton filler and usually having cotton pile yarns. In such fabrics the back may be rendered sufficiently attractive so that it could be used as an alternate for the face and permit reversing the carpet or rug on the floor.

It will further be evident that the thread-in of the invention produces better control of pile and stuffer warp positions and straightness by frequent crossings of the warps with respect to the weft, and reduces lateral shrinkage.

In view of my invention and disclosure, variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art to obtain all or part of the benefits of my invention without copying the process and fabric shown, and I, therefore claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. A pile fabric having a binder warp, at least one pile warp, a stuffer warp and wefts interwoven into a fabric, having the pile warp raised into a pile and having in each course in a particular area of the fabric at least two spaced binder warp ends woven in opposition to all the pile and stuffer warp ends, and at least one warp end between the spaced binder warp ends, and having per course at least one pile warp end arranged in the fabric between binder warp ends.

2. A pile fabric having a binder warp, at least one pile warp, a stuffer warp and wefts interwoven into a fabric, having the pile warp raised into a pile and having at least two spaced binder warp ends per course with at least one warp end interposed between them including one pile warp end, the binder warp ends all being woven in opposition to all of the pile and stuifer warp ends.

3. A pile fabric having a binder warp, at least one pile warp, a stulfer warp and wefts interwoven into a fabric, having the pile warp raised into a pile and having per course in a particular area of the fabric at least one warp end including at least one pile warp end between spaced binder warp ends and at least one stuffer warp end per course outside of the group including the pile warp end between the binder warp ends, the binder Warp ends being woven in opposition to all of the pile and stuffer Warp ends.

4. A pile fabric having a binder warp, at least one pile warp, a stuffer warp and wefts interwoven into a fabric, having the pile warp raised into a pile and having in each course in a particular area of the fabric warp ends including per course at least one pile warp end and at least one stutfer warp end between spaced binder warp ends, and at least one stuffer warp end per course outside of the group including the pile warp end between the binder warp ends, the binder warp ends being woven in opposition to all of the pile and stulfer warp ends.

5. A pile fabric having a binder warp, t least one pile warp, a stuffer warp and wefts interwoven into a fabric, having the pile warp raised into a pile and having per course in a particular area of the fabric warp ends including at least one pile warp end and a plurality of stufier warp ends between spaced binder warp ends and at least one stuffer warp end per course outside of the group including the pile warp end and stuffcr warp ends between spaced binder warp ends, the binder warp ends being woven in opposition to all of the pile and stuffcr warp ends.

6. A pile fabric having a binder warp, at least one pile warp, a stuffer warp and wefts interwoven into a fabric, having the pile warp raised into a pile and having per course in a particular area of the fabric warp ends including at least one pile warp end between spaced stuffer warp ends which in turn are between spaced binder warp ends, and at least one stuifer warp end per course outside of the group including the pile warp end and stuffer warp ends between spaced binder warp ends, the binder warp ends being woven in opposition to all of the pile and stulfer warp ends.

7. A pile fabric having a binder warp, at least one pile warp, a stufier warp and wefts interwoven into a fabric, having the pile warp raised into a pile and having per course in a particular area of the fabric at least one warp end including at least one pile warp end between spaced binder warp ends and a plurality of stuffer warp ends per course outside of the group including the pile warp end between spaced binder warp ends, the binder warp ends being woven in opposition to all of the pile and stuffer warp ends.

8. A pile fabric having a binder warp, at least one pile warp, a stulfer warp and wefts interwoven into a fabric, having the pile warp raised into a pile and having per course in a particular area of the fabric at least one warp end including at least one pile warp end between spaced binder warp ends, and at least one stutfer warp end per course on each side of said spaced binder warp ends, the binder warp ends being woven in opposition to all of the pile and stuffer warp ends.

9. A pile fabric having a binder warp, at least one pile warp, a stuifer warp and wefts interwoven into a fabric, having the pile warp raised into a pile, having at least one end of binder warp interposed between the ends of stutter warp and pile warp, the ends of binder warp all being woven in opposition to the ends of pile warp and stufl'er warp.

10. A pile fabric having a binder warp, at least one pile warp, a stuffer warp and wefts interwoven into a fabric, having the pile warp raised into a pile and having single ends of binder warp interposed between the ends of stuffer warp and pile warp.

11. A pile fabric having a single binder warp, at least one pile warp, at least one stuffer warp and wefts interwoven into a fabric, having the pile warp raised into a pile, having all pile warp ends of a particular course adjoining one another, having at least one end of binder warp on opposite sides of the pile warp end or ends of a particular course, having at least one end of stutfer warp in one course interposed between a binder warp end in that dent and a binder warp end in the adjoining dent and having all ends of binder warp woven in opposition to all ends of pile warp and stuffer warp.

12. A pile fabric having a single binder warp, at least one pilc warp, at least one stuffer warp and wefts interwoven into a fabric, having the pile warp raised into a pile, having all pile warp ends of a particular course adjoining one another, having single ends of binder warp on opposite sides of the pile warp end or ends of a particular dent and having at least one end of stuffer warp in one course interposed between a binder warp end in that course and a binder warp end in the adjoining dent.

13. A pile fabric having a single binder warp, at least one pile warp, at least one stutfer warp and wefts interwoven into a fabric, having the pile Warp raised in the pile, having the binder warp woven in opposition to all pile warp ends and all staffer warp ends, having at least one end of binder warp separating pile warp ends from stuffer warp ends at each position at which pile warp ends and stufl'er warp ends appear, all ends of binder warp being woven in opposition to all ends of pile warp and all ends of stulfer warp.

14. A pile fabric having a single binder warp, at least one pile warp, at least one stuffer warp and wefts interwoven into a fabric, having the pile warp raised in the pile, having the binder warp ends woven in opposition to all pile warp ends and all staffer warp ends and having single ends of binder warp separating pile warp ends from stutfer warp ends at each position at which pile warp ends and stutter warp ends appear.

15. A pile fabric having a single binder warp, at least one pile warp, at least one stuffer warp and wefts interwoven into a fabric, having the pile warp raised in the pile, having the binder warp ends woven in opposition to all pile warp ends and all stufrer warp ends and having binder warp ends at each side of pile warp ends and at each side of stutter warp ends wherever pile warp ends and stulfer warp ends appear in a particular area of the fabric.

16. A pile fabric comprising a binder warp, a plurality of pile warps, at least one stuffer warp and wefts interwoven into a fabric, having at least one of the pile warps raised into a pile, and having at least one end of binder warp interposed between pile warp ends and stuffer warp ends and having the binder warp ends all woven in opposition to the pile warp ends and stutfer warp ends.

17. A pile fabric comprising a binder warp, a plurality of pile warps, at least one stutfer warp and wefts interwoven into a fabric, having at least one of the pile warps raised into a pile, and having single ends of binder warp interposed between pile warp ends and stuffer warp ends.

18. A pile fabric comprising a binder warp, a plurality of pile warps, at least one stuffer warp and wefts interwoven into a fabric, having at least one of the pile warps raised into a pile, and having single ends of binder warp, woven in opposition to the pile warp and to the stuffer warp, interposed between the pile warp ends and the stulfer warp ends.

19. A pile fabric comprising a single binder warp, a pair of pile warps, at least one stuffer warp and wefts interwoven into a fabric, the respective pile warps being raised selectively into the pile at different positions and having single ends of binder warp interposed between ends of the pile warps and the stulfer warp, whereby the pile warp which is not raised in the pile at a particular position appears at the back of the fabric and thus the pattern appears in reverse on the back of the fabric.

20. A pile fabric comprising a single binder warp, a pair of pile warps, at least one stutter warp and wefts interwoven into a fabric, the respective pile warps being raised selectively into the pile at different positions and having single ends of binder warp woven in opposition to the pile warps and to the stuffer warp and interposed between the ends of pile warps in a particular course and the stulfer warp on either side thereto, whereby the pattern appears in reverse at the back of the fabric.

21. A pile fabric having a cotton back and comprising binder warp ends, pile warp ends, stutfer warp ends and wefts interwoven into a fabric, having the pile warp ends 13 raised into a pile, having binder warp ends interposed immediately between pile warp ends and stuifer warp ends and having all of the binder warp ends woven in opposition to the pile warp ends and to the stuffer warp ends.

22. A pile fabric having a single binder warp, at least one pile warp, at least one stuifer warp and wefts interwoven, the pile warp being raised at the face of the fabric, there being in each course at least two ends of binder warp, at least one end of pile warp and at least two ends of stuffer warp, at least one end of binder warp being interposed between the end or ends of pile warp in a particular course and the stuffer warp ends respectively in that dent and in the next dent, and the ends of binder warp all being woven in opposition to the pile warp ends and to the stuffer warp ends.

23. A pile fabric comprising a binder warp, at least one pile warp, at least one stuifer warp and wefts interwoven into a fabric, the pile warp being raised into the pile and bound in the back of the fabric behind at least two wefts between positions at which it is raised in the pile, at least one end of binder warp being interposed between pile warp ends and stutfer warp ends across the fabric and all binder warp ends being woven in opposition to the pile warp ends and stuifer warp ends.

24. A pile fabric having a binder warp, at least one pile warp, a stutfer warp and wefts interwoven into a fabric, having the pile warp raised into a pile and bound in the back behind at least two front wefts between points at which it is raised into the pile, and having per course in a particular area of the fabric at least two spaced binder warp ends woven in opposition to all of the pile and stuffer warp ends and at least one warp end between the spaced binder warp ends, and having per course at least one pile warp end arranged in the fabric between binder warp ends.

25. A pile fabric having a binder warp, at least two pile warps, a stuffer warp and wefts interwoven into a fabric, having the pile warps raised successively in transverse rows in a pile and each pile warp bound in the back behind at least two front wefts between points at which it is raised into the pile, and having per course in a particular area of the fabric at least two spaced binder warp ends woven in opposition to all of the pile and stuffer warp ends and at least one warp end between the spaced binder warp ends, and having per course at least one pile warp end arranged in the fabric between binder warp ends.

26. The process of weaving a pile fabric, which comf tlses threading-in per dent of a particular area of the abric, at least one pile warp end between spaced binder warp ends, and at least one stuffer warp end per dent outside of the group formed by the pile warp end and the spaced binder warp ends, interweaving with wefts the pile warp ends and the stuffer warp ends in opposition to the binder warp ends, and raising pile warp ends in the pile.

27. The process of weaving a pile fabric, which cornprises threading-in per dent at least one pile warp end, at least one stulfer warp end beside the pile warp end, binder warp ends on either side of the pile warp and stuifer warp ends, and at least one. stuffer warp end outside of the group formed by the pile warp and stuffer warp ends between the spaced binder warp ends, interweaving with wefts the pile warp ends and the stulfer warp ends in opposition to the binder warp ends and raising ile warp ends in the pile.

28. The process of weaving a pile fabric, which comprises threading-in per dent at least one pile warp end and a plurality of stuffer Warp ends side by side and between spaced binder warp ends, with at least one stuffer warp end per dent outside of the group of the binder warp end, stuffer warp end and spaced binder warp ends, interweaving with wefts the pile warp ends and the stulfer warp ends in opposition to the binder warp ends and raising pile warp ends in the pile.

29. The process of weaving a pile fabric, which comprises threading-in per dent of a particular. area of the fabric, at least one pile warp end, stuifer warp ends on either side of the pile warp end and at least one binder warp end on either side of the stuifer warp ends just mentioned, with at least one stuffer warp end per dent outside of the group of the binder warp end, stuffer Warp end and spaced binder warp ends, interweaving with wefts the pile warp ends and the stuffer warp ends in opposition to the binder warp ends and raising the pile warp ends in the pile.

30. The process of weaving a pile fabric, which comprises threading-in per dent at least one pile warp end, binder warp ends on either side of the pile warp ends and a plurality of stuffer warp ends per dent outside of the group including the pile warp ends and spaced binder warp ends, interweaving with wefts the pile warp ends and the stuffer warp ends in opposition to the binder warp ends and raising the pile Warp ends in the pile.

31. The process of weaving a pile fabric, which comprises threading-in per dent at least one pile warp end, binder warp ends on each side of the pile warp end, and stuffer warp ends per dent on either side of the binder warp ends, interweaving with wefts the pile warp ends and the stuffer warp ends in opposition to the binder warp ends and raising pile warp ends in the pile.

32. The process of weaving a pile fabric, which comprises threading-in binding warp ends immediately between pile warp ends and stulfer warp ends, interweaving with wefts the pile warp ends and the stuffer warp ends in opposition to the binder warp ends, and raising pile warp ends in the pile.

33. The process of weaving a pile fabric, which comprises threading-in ends of a single binder warp between a pile warp end and a stutfer warp end, raising the binder warp and lowering the other warps to form a lower shed and inserting a shot of weft, raising at least some of the pile warps to an upper position, raising any other pile warps and the stuflfer warp to an intermediate position and lowering the binder warp to a lower position to form upper and lower sheds, inserting a wire into the upper shed and inserting a shot of Weft into the lower shed, all binder warp ends being Woven in opposition to the pile warp ends.

34. The process of weaving a pile fabric, which comprises threading-in single ends only of a single binder warp between a pile warp end and a stuffer warp end, raising the binder warp and lowering the other warps to form a lower shed and inserting a shot of weft, raising at least some of the pile warps to an upper position, raising any other pile warps and the stuifer warp to an intermediate position and lowering the binder warp to a lower position to form upper and lower sheds, inserting a wire into the upper shed and inserting a shot of weft into the lower shed, all binder warp ends being woven in opposition to the pile warp ends.

35. The process of weaving a pile fabric, which comprises threading-in pile warp ends of at least two pile warps, binder warp ends and stuffer warp ends through dents with a binder warp end interposed between a pile warp end and a stuifer warp end respectively in the same dent and in the adjoining dent, interweaving with wefts the pile warp ends and stuffer warp ends in opposition to all of the binder warp ends, raising at least some of the ends of one pile warp in the pile at one position, raising at least some of the ends of another pile warp in the pile at another position, and concurrently forming a pattern of pile warp ends at the back of the fabric.

36. The process of weaving a pile fabric which comprises threading in pile warp ends of at least two pile warps, single binder warp ends and stutfer warp ends through dents with a binder warp end interposed between a pile warp end and a stulfer warp end respectively in the same dent and in the adjoining dent, interweaving with wefts the pile warp ends and stutfer warp ends in opposition to all of the binder warp ends, raising 15 at least some of the ends of one pile warp in the pile at one position, raising at least some of the ends of another pile warp in the pile at another position, and concurrently forming a pattern of pile warp ends at the back of the fabric.

37. The process of weaving a pile fabric, which comprises interthreading pile warp ends of two pile warps, binder warp ends of a single binder warp and stuffer warp ends through dents with a binder warp end interposed between two pile warp ends and a stulfer warp end throughout, interweaving with wefts the pile warps and the stuffer warp in opposition to the binder warp, selectively raising at least some of the pile warp ends of one pile warp in the pile at one position, selectively raising at least some of the pile warp ends of the other pile warp in the pile at another position, and concurrently forming a pattern of the rejected pile warp ends at the back of the fabric.

38. The process of Weaving a pile fabric, which comprises interthreading pile warp ends of two pile warps, binder warp ends of a single binder warp and stuffer warp ends through dents with a single binder warp end interposed between two pile warp ends and a stutter warp end throughout, interweaving with wefts the pile warps and the stufler warp in opposition to the binder warp, selectively raising at least some of the pile warp ends of one pile warp in the pile at one position, selectively raising at least some of the pile warp ends of the other i position, raising other pile warp ends and the stulfer warp to an intermediate position and lowering the binder warp to a lower position to form upper and lower sheds, inserting a Wire into the upper shed and inserting a shot of weft into the lower shed, all binder warp ends being Woven in opposition to the pile warp ends, the respective pile warp ends being bound in the back of the fabric behind at least two front wefts between successive points at which they are raised over wires.

References Cited in the file of this patent UNITED STATES PATENTS 642,740 Duquesne Feb. 6, 1900 912,666 Gledhill Feb. 16, 1909 FOREIGN PATENTS 814,846 France Mar. 30, 1937 

